Ford Five Hundred 2005-2007 Service Repair Workshop Manual
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🏷️ Basic Information Identification Make: Ford Model: Five Hundred Model Years Covered: 2005, 2006, 2007 Codes Platform: Ford D3 Platform 👋 Introduction Market Position Positioning: A premium, full-size sedan offering comfort and space, positioned as a family-oriented vehicle in its segment. Competitive Analysis Key Competitors: Buick LaCrosse, Toyota Avalon, Chrysler 300, Dodge Charger, Mercury Montego. Key Features Platform Sharing: Shared the D3 platform with Volvo S80 and XC90, contributing to its robust chassis and safety. Design Philosophy: Emphasized a comfortable, quiet ride and spacious interior, with a focus on practicality for families. 📋 Manual Details Coverage Areas Technical Scope: Comprehensive service, repair, diagnosis, and troubleshooting Target Audience: Professional mechanics and knowledgeable DIY enthusiasts Page Count Estimated Page Count: Varies by specific edition, typically over 2000 pages Manual Type Type: Factory Service Manual / Workshop Manual Language Language: English Format Format: Digital (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed procedures for disassembly, assembly, inspection, and repair of engine components. Engine Electrical: Wiring diagrams, diagnostic procedures for ignition, charging, starting systems, and sensors. Emission Control: Diagnosis and repair of emissions-related systems, including EGR, O2 sensors, and catalytic converters. Fuel System: Fuel injection system diagnosis, fuel pump, injectors, fuel pressure testing, and fuel tank service. Clutch System: Service and repair procedures for clutch assembly and related components (for manual transmission variants). Manual Transaxle: Complete repair and maintenance of the manual transaxle, including gear inspection and synchronization. Automatic Transaxle: Detailed overhaul, diagnosis, fluid changes, and electronic control module (TCM) procedures for the automatic transmission. Driveshaft Axle: Inspection, repair, and replacement of driveshafts, CV joints, and wheel bearings. Suspension System: Front and rear suspension component diagnosis, replacement (struts, shocks, control arms, bushings), and alignment specifications. Steering System: Power steering system diagnosis, pump, rack and pinion repair, and steering column service. Restraint System: Airbag system diagnosis, SRS module, seatbelt service, and occupant restraint component repair. Brake System: Disc brake service (pads, rotors), caliper repair, ABS system diagnosis, hydraulic lines, and parking brake. Body Interior Exterior: Body panel alignment, door, hood, trunk service, interior trim removal and installation, glass replacement. Body Electrical System: Lighting systems, power windows, door locks, mirrors, wipers, horn, and body control module (BCM) diagnostics. HVAC System: Air conditioning system diagnosis, refrigerant handling, blower motor, evaporator, condenser, and heater core service. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and changes, spark plug replacement, belt replacement. Troubleshooting: Diagnostic flowcharts, common symptom-based troubleshooting guides, and error code explanations. Repair: Step-by-step instructions for component replacement and repair, including torque specifications. Diagnostics: Procedures for using diagnostic scan tools, interpreting data streams, and pinpointing electrical or mechanical faults. Technical Depth Depth: Factory-level detail, suitable for complete engine rebuilds, transmission overhauls, and complex electrical diagnostics. 📊 Manual Specifications File Format File Type: PDF Print Quality Printability: Fully printable; individual pages can be printed for workshop use. Binding Type Binding: N/A (Digital Format) Paper Type Paper Quality: N/A (Digital Format) Compatibility Operating Systems: Compatible with all versions of Windows and macOS. Requirements Software: Adobe PDF Reader required for viewing. ⚙️ Engine Specifications Primary Engine Engine Model: Ford Duratec 30 (3.0L V6) Engine Code: AJ30 Performance Horsepower: 203 hp @ 6250 rpm (approx.) Torque: 207 lb-ft @ 4250 rpm (approx.) Fuel System Injection Type: Sequential Electronic Fuel Injection (SEFI) Engine Mechanical Bore X Stroke: 89 mm x 79.5 mm (approx.) Compression Ratio: 9.7:1 (approx.) Valve Train: Dual Overhead Camshafts (DOHC), 4 valves per cylinder 🔧 Transmission Standard Transmission Type: 6-speed Automatic Transaxle (CD4E derived) Optional Transmission Type: Not applicable for standard models; manual was not offered. Features Drive Type: Front-Wheel Drive (FWD) or All-Wheel Drive (AWD) Fluid Specifications Automatic Transmission Fluid: Mercon V (Refer to manual for exact specification and capacity) 📐 Dimensions Exterior Length: 200.4 inches (approx.) Width: 76.5 inches (approx.) Height: 57.9 inches (approx.) Wheelbase: 114.4 inches (approx.) Interior Passenger Volume: 107.4 cubic feet (approx.) Cargo Trunk Volume: 16.1 cubic feet (approx.) Weights Curb Weight: 3,595 - 3,828 lbs (approx.) 🛡️ Safety Features Ratings NHTSA Front Impact Driver: 5 Stars NHTSA Front Impact Passenger: 5 Stars IIHS Frontal Offset: Good Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Standard Traction Control System (TCS) Electronic Stability Control: Optional Electronic Stability Control (AdvanceTrac) Passive Features Airbags: Standard front airbags, optional side-curtain airbags. 💡 Technology Features Infotainment Audio System: Available AM/FM/CD player, optional premium audio systems, SiriusXM satellite radio. Navigation: Optional factory navigation system was available. Driver Assistance Parking Assist: Optional rear parking assist sensors. Connectivity Remote Start: Optional factory remote start system. 🔧 Maintenance Service Intervals Oil Change Interval: Every 5,000 miles or 6 months, whichever comes first (synthetic blend recommended). Engine Air Filter: Inspect every 15,000 miles, replace as needed or every 30,000 miles. Spark Plugs: Replace every 100,000 miles (Long-life platinum or iridium plugs recommended). Transmission Fluid Change: Every 100,000 miles or as per...